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JH Industries Copperloy EDGE-OF-DOCK SEL Series Installation & Owner's Manual

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EDGE-OF-DOCK
SEL Series
Installation
&
Owner's Manual
Serial No. 75652 to Present
by
JH
I N D U S T R I E S , I N C .
1981 E. Aurora, Rd.
Twinsburg, Ohio 44087
Model #__________________________
(330) 963-4105 (Phone)
Serial #__________________________
1-800-321-4968 (Toll Free)
Date: __________________________
www.copperloy.com
WARNING
!
Do not install, operate or service this product unless you have read and understand the Safety
Practices, Warnings, Installation and Operating Instructions contained in this manual. Failure to
do so could result in serious injury or death.
REV: 4/2023

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Summary of Contents for JH Industries Copperloy EDGE-OF-DOCK SEL Series

  • Page 1 EDGE-OF-DOCK SEL Series Installation & Owner’s Manual Serial No. 75652 to Present I N D U S T R I E S , I N C . 1981 E. Aurora, Rd. Twinsburg, Ohio 44087 Model #__________________________ (330) 963-4105 (Phone) Serial #__________________________ 1-800-321-4968 (Toll Free) Date: __________________________ www.copperloy.com...

  • Page 3: Warranty

    J H Industries, Inc. products are specifically DISCLAIMED. INTRODUCTION Welcome, and thank you for purchasing your dock leveler from Copperloy by JH Industries. It is designed to give you years of trouble-free operation. This manual contains information that is needed to operate and maintain the leveler safely. It also contains a complete parts list and information about ordering replacement parts.

  • Page 4: Table Of Contents

    JH INDUSTIRES INC. TABLE OF CONTENTS WARRANTY…………………….. HYDRAULIC SCHEMATIC…….. INTRODUCTION……………….. SINGLE PHASE 120VAC TABLE OF CONTENTS……….. ELECTRICAL SCHEMATIC….. SAFETY…………………………. 1-PHASE 120VAC SAFETY PRACTICES…………. ENCLOSURE ASSEMBLY…….. GRADE CHART………………… SINGLE PHASE 230VAC CAPACITY………………………. ELECTRICAL SCHEMATIC….. OWNER’S RESPONSIBILITIES… PARTS 1-PHASE PARTS………. INSTALLATION…………………. 8-12 1-PHASE INSTALLED GENERAL INSTALLATION…….

  • Page 5: Safety Practices

    JH INDUSTIRES INC. SAFETY PRACTICES DO NOT operate the dockleveler with equipment, WARNING material, or people on or in the path of the ramp or Read and follow all safety practices, placards lip. and owners manual warnings before installing, DO NOT operate the dockleveler when anyone is in operating or servicing the Dockleveler.

  • Page 6: Grade Chart

    JH INDUSTIRES INC. SAFETY PRACTICES, CONTINUED INSTALLATION, MAINTENANCE AND SERVICE All electrical troubleshooting or repair must be done by a qualified technician and must meet applicable codes. Place barricades on the dock floor around the dock leveler final location and in the driveway in front of the dockleveler final location while installing, If it is necessary to make troubleshooting checks inside the control box with the power on, USE...

  • Page 7: Capacity

    JH INDUSTIRES INC. CAPACITY CALCULATING CAPACITY More than 8 trucks serviced per day Determining required leveler capacity: Determine Three-Wheeled fork trucks (14,000# GVW or less) gross vehicle weight (GVW = lift truck weight + battery + heaviest load) of the largest lift truck to be Fork trucks travel faster than 3-mph used.

  • Page 8: Owner's Responsibilities

    JH INDUSTIRES INC. OWNER’S RESPONSIBILITIES The owner’s responsibilities include the following: Modifications or alterations of dock leveling devices The owner should recognize the inherent danger of the shall be made only with written permission of the interface between dock and transport vehicle. The original manufacturer.

  • Page 9: Installation

    JH INDUSTIRES INC. INSTALLATION, CONTINUED INSTALLATION WITH FIGURE 3 WELD FLAT TRANSITION PLATE CURB DOCKLEVELER CHANNEL MOUNTING PLATE 1. Lay the transition plate on top of dock. 2. If using a beveled transition plate (Model: TPBF12) position transition plate flush with the front of dock edge and skip to step 6.
  • Page 10 JH INDUSTIRES INC. INSTALLATION, CONTINUED INSTALLATION WITH FIGURE 6 FORMED ANGLE REMOVE CONCRETE AS REQUIRED (2” MAX IN EACH 1. Lay formed angle on top of dock. DIRECTION). FILL IN WITH MODEL: TPBL24 CONCRETE AS REQUIRED 2. If using a beveled formed angle (Model: TPBL24) BEVELED position formed angle on dock making sure both FORMED ANGLE...
  • Page 11 JH INDUSTIRES INC. INSTALLATION, CONTINUED INSTALLATION WITH FIGURE 8 STEEL APPROACH RAMP DOCKLEVELER STEEL WELD 1. Position the Steel Approach Ramp flush with the MOUNTING PLATE APPROACH front face of dock. (See Figure 8). 2. Install anchor bolts in the steel approach ramp. All anchor bolts to be a min.
  • Page 12 JH INDUSTIRES INC. INSTALLATION, CONTINUED INSTALLATION WITH RECESSED PIT 1. Use a minimum 12” x 13” pit recess with an additional 3” of clearance per side of leveler (See Figure 9 & 10). 2. Follow section that addresses your installation and then continue to the GENERAL INSTALLATION section on pages 13 &...

  • Page 13: General Installation

    JH INDUSTIRES INC. GENERAL INSTALLATION WARNING 5. While one person holds the hand lever down as Read and follow Safety Practices on page 2. shown in (Figure 18), with the use of the plate Failure to follow these safety practices could clamp, carefully lower lip to the full back position result in property damage, serious injury or as shown in (Figure 18).
  • Page 14 JH INDUSTIRES INC. GENERAL INSTALLATION, CONTINUED WARNING 9. Continuously weld dockleveler mounting plate to curb channel, transition plate, angle plate or Do not over-adjust the extension springs. steel approach ramp in accordance with AWS Over-adjusting extension springs may cause the Standards.

  • Page 15: Hydraulic Installation

    JH INDUSTIRES INC. HYDRAULIC INSTALLATION WARNING Before installing the dockleveler, read and FIGURE 13 follow Safety Practices on pages 5 & 6. Power to control box must be from a fused disconnect supplied by others. For correct fuse size refer to Wiring Diagram section of this manual.
  • Page 16 JH INDUSTIRES INC. HYDRAULIC INSTALLATION, CONTINUED HYDRAULIC CYLINDER CONNECTION FIGURE 15 6. Locate and weld Hydraulic Cylinder upper UPPER MOUNTING mounting bracket to the dockleveler ramp plate BRACKET as shown. (See Figure 14). ROD EYE 7. With the dockleveler in the rest position, adjust the hydraulic cylinder rod eye so that the rod eye hole center is about 3-1/2”...
  • Page 17 JH INDUSTIRES INC. HYDRAULIC INSTALLATION, CONTINUED STANDARD 10”x13”x4” MOLDED BUMPER (2-Hole) LEVELER WIDTH 4-1/2” 1-1/2” 13” 32” 12” 12” LIP AND RAMP NOT SHOWN FOR CLARITY 29” 12” OPTIONAL 12”x13”x4” MOLDED BUMPER (4-Hole) LEVELER WIDTH 1-1/2” 4-1/2” 13” 32” 15” 15”...
  • Page 18 JH INDUSTIRES INC. HYDRAULIC INSTALLATION, CONTINUED NOTE: TO FUSED DISCONNECT A JUNCTION BOX SUPPLIED BY THE OWNER SUPPLIED BY OTHERS SEE OR CONTRACTOR CAN BE USED AT ANY FUSING REQUIREMENTS POINT BEFORE THE MOTOR. PROVIDED BELOW LAYOUTS FOR INFORMATIONAL PURPOSES ONLY.

  • Page 19: Operation

    JH INDUSTIRES INC. OPERATION WARNING Moving the hand lever back moves the ramp to the Before operating the dockleveler, read and full raised position, engaging the lip extension link. follow Safety Practices on pages 5 & 6. Moving the lever forward extends the dockleveler lip onto the truck.
  • Page 20 JH INDUSTIRES INC. OPERATION, CONTINUED FIGURE 17 FIGURE 19 WARNING Keep both hands firmly on the hand lever while Once dockleveler is resting securely raising or lowering the dockleveler. Keep other on truck bed, remove hand lever. body parts clear of hand lever travel path while (See Figure 20).
  • Page 21 JH INDUSTIRES INC. OPERATION, CONTINUED WARNING FIGURE 22 Never use a fork truck or other material handling equipment to lower the ramp and lip section. 6. Proceed with loading or unloading. 7. Return the dockleveler to the stored position when entry to the truck is no longer required. Re-insert hand lever, into lever socket located on right side of ramp plate.
  • Page 22 JH INDUSTIRES INC. OPERATION, CONTINUED by the truck bed. HYDRAULIC OPERATION Never use a fork truck or other material handling WARNING equipment to lower the ramp and lip section. Before operating the dockleveler, read and 8. When done using the unit, push the “UP” button follow Safety Practices on page 5 &...

  • Page 23: Maintenance

    JH INDUSTIRES INC. MAINTENANCE WARNING FIGURE 23 Before servicing the dockleveler, read and follow all Safety, Warnings and Manuals. STAND CLEAR! The dockleveler moves toward you. Always be certain the ramp is in the raised position, SECURED WITH THE MAINTENANCE STRUT (See Figure...
  • Page 24 JH INDUSTIRES INC. Inboard Handle Maintenance, CONTINUED INSERT MAINTENANCE STRUT WARNING Do not use hands or feet to hold lip extender link 1. (Hydraulic Only) While in the rest position (See disengaged. Use of hands or feet could cause a Figure 16) remove the Rod Eye Bolt from the pinch point resulting in serious injury or death.
  • Page 25 JH INDUSTIRES INC. MAINTENANCE, CONTINUED D. Fina Oil Co. 8. Every 6 months verify that this is the latest and Fina AW 32, 46 most up to date manual by visiting the Fina Automatic Transmission Fluid manufacturer’s website. (Download or order as Dexron II needed) E.
  • Page 26 JH INDUSTIRES INC. MAINTENANCE SCHEDULE Check hydraulic reservoir oil level. Fill with hydraulic oil. See pg. 25 for oil type Check the breather vent is in the correct Install the vent cap in the See pg. 16 of this manual location and is free and clear.

  • Page 27: Trouble Shooting

    JH INDUSTIRES INC. TROUBLE SHOOTING Issue Cause Repair Verify EOD linkage is able to rotate onto the roller when the EOD is Grind the area of the linkage that rests on the roller slightly in the full back pos on. The linkage should move freely and have a to increase the amount of clearance.

  • Page 28: Standard Parts List

    JH INDUSTIRES INC. STANDARD PARTS LIST Part # tem Qty. Part Description 20K Capacity 30K Capacity 1 Vinyl Handle Grip 024-023 024-023 1 Handle Lever w/ vinyl handle grip 095-352 095-352 1 Extender Linkage SEL-02-00033 SEL-02-00033 1 5/8"-2-1/2" Clevis Pin SEL-05-00001 SEL-05-00001 3 5/8"-2"...

  • Page 29: Inboard Handle Parts List

    JH INDUSTIRES INC. INBOARD HANDLE PARTS LIST Part # Item Qty. Part Description 20K Capacity 30K Capacity 1 Handle End Cap SEL-04-00016 SEL-04-00016 1 Inboard Handle Lever w/ Removable Cap SEL-02-00060 SEL-02-00060 1 Inboard Socket Sub-weldment SEL-01-00009 SEL-01-00006 Tapered PLATE RAMP PLATE MOUNTING...

  • Page 30: Standard Bumper Parts

    JH INDUSTIRES INC. STANDARD BUMPER PARTS LIST Item Qty. Description Part # Complete bumper block assembly, 2-Hole SEL-01-00094 10"x13"x4" Molded Rubber Bumper (Standard) SEL-04-00011 Scr, Hx, Gr2, 3/4"-10 002-163 Wshr, Fl, Standard, 3/4" 002-156 Nut, Center Lock, 3/4"-10 002-159 10x13x12, Steel Block Weldment (2-Hole) SEL-01-00082 OPTIONAL BUMPER PARTS LIST Item Qty.

  • Page 31: Label Parts List

    JH INDUSTIRES INC. LABEL PARTS LIST SEL-12-00054-B EOD Danger Label (Place on underside of Ramp Plate Typ. of one) SEL-12-00053-C EOD Danger Label (Place on exterior side of left bumper & interior side of right bumper Typ. of two ) SEL-12-00050-B Hydraulic EOD Danger SEL-12-00056-B Mechanical EOD Danger Placard (Post near EOD Typ.
  • Page 32 JH INDUSTIRES INC. LABEL PARTS LIST EOD SEL Hydraulic Power Pack Labels SEL-12-00053-C EOD Danger Label (Place on exterior side of left bumper & interior side of right bumper Typ. of two ) SEL-12-00101 EOD Warning Label (Place on hydraulic electric box lined up with holes for pushbuttons ) SEL-12-00071 EOD Danger Label (Place on hydraulic electrical box centered on box front )

  • Page 33: Hydraulic Schematic

    JH INDUSTIRES INC. HYDRAULIC SCHEMATICS...
  • Page 34 JH INDUSTIRES INC. SINGLE PHASE 120VAC ELECTRICAL SCHEMATIC MOTOR WIRING DIAGRAM WARNING LOW VOLTAGE Before doing any electrical work, make certain that all power sources are disconnected and properly tagged or locked out per OSHA requirements. All electrical work must be done by a qualified technician and must meet all applicable codes.

  • Page 35: Single Phase 120Vac Electrical Schematic

    JH INDUSTIRES INC. SINGLE PHASE 120V ENCLOSURE ASSEMBLY Item Qty. Description Part # 1 120V, Single Phase Control Box Assembly 06-00129 1 Contactor, 18amp, 120VAC Coil 06-00121 1 Overload, 12-18amps 06-00127 2 Pushbutton 063-026 1 6.25"x9.50"x5.75", Nema 12 Enclosure 063-027 1 12 Pole Terminal Block 06-00006 4 Line-toLine Terminal Block Jumpers...

  • Page 36: Single Phase 230Vac Electrical Schematic

    JH INDUSTIRES INC. SINGLE PHASE 230V ELECTRICAL SCHEMATIC MOTOR WIRING DIAGRAM WARNING Before doing any electrical work, make certain that HIGH VOLTAGE all power sources are disconnected and properly tagged or locked out per OSHA regulations. electrical work must be done by a qualified technician and must meet all applicable codes.

  • Page 37: Parts 1-Phase Parts

    JH INDUSTIRES INC. SINGLE PHASE 230V ENCLOSURE ASSEMBLY Item Qty. Description Part # 1 230V, Single Phase Control Box Assembly 06-00130 1 Contactor, 18amp, 230VAC Coil 06-00122 1 Overload, 5.5-8amps 06-00126 2 Pushbutton 063-026 1 6.25"x9.50"x5.75", Nema 12 Enclosure 063-027 1 12 Pole Terminal Block 06-00006 4 Line-toLine Terminal Block Jumpers...

  • Page 38: 1-Phase Installed Assembly

    JH INDUSTIRES INC. PARTS 1-PHASE INSTALLED ASSEMBLY 1-Phase Voltage Item # Qty. Description 120VAC 230VAC Hydraulic Power Pack, Assembly 7649DA 7649DA 5/16"-18x1.00" HH Scr Grd 5 002-054 002-054 5/16" Flat Washer 046-004 046-004 5/16"-18 Rev. Lock Nut 024-010 024-010 5/8"-11 Rev. Lock Nut 002-047 002-047 5/8"-11x2-3/4"...

  • Page 39: Schematic

    JH INDUSTIRES INC. 3-PHASE ELECTRICAL SCHEMATIC 230/460V, 3-PHASE, 50/60 Hz, (WALL MOUNT PUSH BUTTON) WIRE CONNECTIONS (IN FIELD): Disconnect to Terminal Block Connections Disconnect L1 (12ga. Black) to A105 Disconnect L2 (12ga. Red) to A103 Disconnect L3 (12ga. Blue) to A102 Disconnect Ground (12ga.

  • Page 40: Parts 3-Phase Enclosure Assembly

    JH INDUSTIRES INC. PARTS– 3-PHASE ENCLOSURE ASSEMBLY Item Qty. Description Part # 1 230VAC/460VAC, 3-Phase Control Box Assembly 06-00132/06-00133 1 Contactor, 17amp, 24VAC Coil 06-00120 1 Overload, (230VAC 2.5-4.0A/460VAC 1.6-2.5A) 06-00125/06-00124 2 Pushbutton 063-026 1 6.25"x9.50"x5.75", Nema 12 Enclosure 063-027 2 7 Pole Terminal Block 06-00007 4 Line-toLine Terminal Block Jumpers...

  • Page 41: 3-Phase Installed Assembly

    JH INDUSTIRES INC. PARTS 3-PHASE INSTALLED ASSEMBLY 3-Phase Voltage Item # Qty. Description 208/230VAC 460VAC Hydraulic Power Pack, Assembly 7681DA 7681DA 5/16"-18x1.00" HH Scr Grd 5 002-054 002-054 5/16" Flat Washer 046-004 046-004 5/16"-18 Rev. Lock Nut 024-010 024-010 5/8"-11 Rev. Lock Nut 002-047 002-047 5/8"-11x2-3/4"...
  • Page 42 JH INDUSTIRES INC. JH Industries, Inc. 1981 E. Aurora Road Twinsburg, OH 44087 Phone: 1-330-963-4105 Fax: 1-330-963-4111 Toll Free: 1-800-321-4968 www.copperloy.com...

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